Engine removal Remove:
- the adjusters at the end of the camshafts, - the TDC pin plug.
14491-1R
Turn the engine clockwise (timing end) until the crankshaft touches the TDC pin.
Positioning the timing at the setting point Method
Position the camshaft grooves downwards as shown on the diagram below.
14491R
14489S
Screw in the TDC pin (1).
Engine repair 10
The camshaft grooves should be horizontal and out of line towards the bottom as shown in the diagram below.
14490S
Slacken nut (3) on the tension wheel.
Fit the flywheel locking tool (Mot. 582-01).
14487-7R
Remove:
- the accessories crankshaft pulley, - the intermediate timing cover (1), - the upper timing cover (2),
Engine repair 10
14839R
Remove:
- the timing belt,
- the camshaft pulleys using tool Mot. 1490,
Engine repair 10
14497R
- the various components in diagrams 1 to 12.
1
Engine repair 10
14497-1S
2
Engine repair 10
14497-2S
3
Engine repair 10
14497-3S
4
Engine repair 10
14497-4R
Remove the cylinder head cover bolts,then use a copper hammer to tap on lugs (1) and remove the cylinder head cover vertically.
5
Engine repair 10
14498S
6
Engine repair 10
14498-1S
7
Engine repair 10
14501S
8
Engine repair 10
14501-1S
9
Engine repair 10
14502S
- the lower inlet distributor.
14503S
Remove:
- the coolant housing at the end of the cylinder head,
10
11
Engine repair 10
14500S
Compress the valve springs using a valve lifter.
Remove:
- the keys, - the upper cups, - the springs, - the valves,
- the valve guide seals using pliers Mot. 1335.
CLEANING
It is very important to avoid scratching the gasket faces of parts in aluminium.
Use Décapjoint to dissolve any gasket remaining on the surface.
Apply the product to the area to be cleaned, wait for approximately ten minutes then remove it using a wooden spatula.
12
Engine repair 10
Gloves should be worn during the operation.
Do not allow the product to come into contact with paintwork.
This operation must be carried out with extreme care to avoid any foreign bodies entering the oil-ways bringing oil under pressure to the hydraulic tappets, camshafts (oilways are located both in the cylinder block and the cylinder head) and the oil return pipe.
If this precaution is not observed, the various oil-ways may become blocked, causing rapid damage to the engine.
CHECKING THE GASKET FACE
Use a set of shims to check for gasket face bow.
Maximum deformation 0.05 mm
The cylinder head may not be reground.
Check the cylinder head for any cracking.
Engine repair 10
Checking the camshaft end play Refit:
- the camshafts in the correct position (refer to camshaft identification in the "Specifications" section), - the cylinder head cover, tightening it to the correct torque.
Tightening method
Fitting Bolt tightening order Bolt slackening order Tightening torque (in daN.m)
Operation n° 1 22-23-20-13 - 0.8
Operation n° 2 1 to 12
14 to 19 21 and 24
- 1.2
Operation n° 3 - 22-23-20-13
-Operation n° 4 22-23-20-13 - 1.2
Engine repair 10
Check the end play which should be between 0.08 and 1.78 mm.
14519S
NOTE : to fit the magnetic base onto the cylinder head, use tool Mot. 588 and secure it using the oil decanter mounting bolts (1) and the spacers (2) which have the following dimensions:
- external diameter 18 mm,
- diameter of hole for bolt (1) 9 mm, - height 15 mm.
14519R
Remove the cylinder head cover and the cams-hafts again.
Engine repair 10
REFITTING THE CYLINDER HEAD
Fit the new valves, gently lapping them in on their respective seats. Thoroughly clean and mark all the parts then proceed with the refitting opera-tions.
Lubricate the inside of the valve guide.
Fit the new valves.
Fit:
- the seals in turn (non-lubricated) to the valve guides using a pipe wrench,
- the springs, - the upper cups.
Compress the springs.
Fit the keys.
Engine repair 10
Remove the various components in diagrams 1 to 8.
14504S
14505S
14505-1S
14505-2S
1
2
3
4
Engine repair 10
14506S
14506-1S
14506-2S
IMPORTANT: never use a punch for marking the big end caps in relation to their bodies, to avoid starting any cracking in the connecting rod. Use an indelible pencil.
The crankshaft bearing caps (the bearing caps are numbered from 1 to 5).
5
6
7
8
Engine repair 10
14525R
Refitting the engine Clean the cylinder block.
Fitting the gudgeon pins
The gudgeon pins are press fitted in the connec-ting rods and are fully floaconnec-ting in the pistons. Use tool Mot. 574-22 supplied in a kit containing:
- a piston support base (S), - an extraction mandrel (1),
- fitting pins (A) with centring devices (C).
It is vital to note the position of the crankshaft bearing shells as the class may differ for each bea-ring.
Removing the gudgeon pins
Place the piston in the V of the support, with the gudgeon pin aligned with the release hole.
Using the extraction mandrel (1), remove the pin from the piston on the press.
10052R
Engine repair 10
76716R
PREPARATION OF THE GUDGEON PINS
Check that the gudgeon pins slide freely in their corresponding new piston.
Use the centring device C13 and the fitting pin A13 or Mot. 574-24.
Fit the gudgeon pin (E) to the fitting pin (A), screw in the centring device (C) until it makes contact then slacken it by a quarter turn.
PREPARATION OF THE CONNECTING RODS Visually check:
the condition of the connecting rods (twisting -squareness),
- the contact of the bearing caps on the body of the connecting rods (if necessary use a stone to remove any burring, to ensure a correct seat).
Use a 1 500 W heating plate.
Place the little ends on the heating plate.
Check that the complete surface of the little end is in contact with the plate.
On each little end, place a small piece of solder at (A) as a temperature guide, as it fuses at approxi-mately 250 °C.
Heat the little end until the solder melts.
DI1038
Engine repair 10
14513R
To assemble the piston and connecting rod, fol-low the instructions befol-low:
Place ring B10 on the base and place the piston on the ring, securing it using the pin.
Check that the gudgeon pin hole is aligned with the hole in ring B10.
ASSEMBLING THE "CONNECTING ROD - PISTONS"
The pistons are marked by a Λ on their crown indi-cating the flywheel end.
Positioning the pistons in relation to the connec-ting rods
Ensure the Λ (1) on the piston crown is at the top.
Ensure the connecting rod bearing shell stop lug (2) is at the bottom.
14524R
Lubricate the centring device and the gudgeon pin using engine oil.
Press the gudgeon pin in to check that it slides freely and, if necessary, recentre the piston.
Engine repair 10
The following operations should be carried out quickly to avoid heat loss as far as possible.
When the piece of solder has reached the point of fusion (transformation into a droplet) :
- wipe off the drop of solder,
- fit the centring guide into the piston, - fit the connecting rod into the piston,
- press the gudgeon pin in as quickly as possible until the guide touches the bottom of the sup-port base.
Check that the gudgeon pin remains inside the diameter of the piston for all positions of the connecting rod in the piston.
Crankshaft Fit:
- the non-grooved bearing shells on bearing caps 1 - 3 - 5,
- the grooved bearing shells on the bearings for the cylinder block and on bearing caps 2 - 4, - the crankshaft side shims on bearing 3 (grooves
at crankshaft end),
Refit the crankshaft bearing caps (these are numbered 1 to 5) and initially tighten the bolts to 2.5 daN.m then angle tighten by 47° ± 5°.
14506-3S
NOTE : remember to apply a fine layer of RHODORSEAL 5661 to bearing n° 1 in zone (A).
Engine repair 10
Aligning the piston rings on the piston
Ensure the piston rings are positioned as shown on the diagram below.
Check the side clearance for the crankshaft which should be between 0.045 and 0.252 mm without wear and 0.045 and 0.852 mm with wear.
Check the crankshaft turns freely.
FITTING THE PISTON RINGS
The piston rings, which are set in the factory, must move freely in their grooves.
Ensure the rings are fitted in the correct manner, TOP should be at the top.
14526S
14514S
Engine repair 10
- the crankshaft closure plate, sealed using Loctite 518. Bead (B) should be 0.6 to 1 mm wide and should be applied as shown in the diagram below, tightening to a torque of 1.1 daN.m in the recommended order.
REFITTING
Lubricate the pistons.
Fit the piston and connecting rod assemblies into the cylinder block using the ring (example : FACOM 750 TB), ensuring the direction is correct (Λ towards the flywheel).
Fit the connecting rod onto the lubricated crankshaft crankpins.
Fit the big end caps.
Tighten the new nuts for the big end caps to a torque of 4.3 daN.m.
Refit :
- the oil pump chain,
- the oil pump and torque tighten it to 2.2 to 2.7 daN.m,
14506-1R
10061-1R
Engine repair 10
- Timing end, use tool Mot. 1385.
Refit :
- the anti-emulsion plate,
- the sump with a new gasket, pre-tightening it to 0.8 daN.m then finally tighten (in a "snail"
pattern) to 1.4 daN.m. The alignment of the cylinder block and the sump must be observed on the flywheel side to avoid deforming the clutch housing when assembling with the gearbox.
Fitting the crankshaft seals
- Flywheel end, use tool Mot 1129-01.
14522R
14523R
Refit :
- the flywheel, tightening the new bolts to a torque of 5.5 daN.m (tighten in star pattern), - the clutch, tightening to a torque of
1.8 daN.m.
Engine repair 10
Refit the water pump, sealing it using Loctite 518.
Bead (C) should be 0.6 to 1 mm wide and should be applied as shown in the diagram below.
10063R
Refit :
- the timing tension wheel, correctly positioning the pulley lug in the groove (A),
Pretighten the M6 and M8 bolts to 0.8 daN.m then tighten the M6 bolts to 1.1 daN.m and the M8 bolts to 2.2 daN.m in the recommended order.
NOTE : apply 1 or 2 drops of Loctite FRENETANCH to bolts 1 and 4 on the water pump.
14505-1R
Engine repair 10
REFITTING THE CYLINDER HEAD
Position the pistons half way.
Fit tool Mot. 104 to the cylinder block.
14689R
14503S
Fit the cylinder head gasket then the cylinder head.
Check the bolts then tighten the cylinder head (refer to the "Cylinder head specifications"
section).
NOTE : Check:
- the alignment between the lower inlet
distributor and the cylinder head (timing end), - the alignment between the upper faces (1) of
the lower inlet distributor and the cylinder head.
Refit the coolant housing with a new seal and torque tighten it to 1 daN.m.
Refit the lower inlet distributor, tightening it to a torque of 2 daN.m.
Engine repair 10
14501-1R
Refit :
- the exhaust manifold, torque tightening it to 1.8 daN.m in the re-commended order,
Engine repair 10
14501R
- the upper exhaust heat shield, torque tightening it to 1 daN.m, - the oxygen sensor, torque tightening it to 4.5 daN.m.
NOTE : check that the exhaust heat shield is correctly positioned between the oxygen sensor and the manifold (this prevents the chimney effect which would destroy the oxygen sensor connections).
- the strut between the exhaust manifold and the cylinder block, - the spacer (A).
Engine repair 10
14499R2
After a certain time, the hydraulic tappets will drain and must be reprimed.
To check if they need to be reprimed, press on the top of the stop at (A) using a thumb. If the stop piston goes down, immerse it in a container of diesel.
Refit the hydraulic tappets and valve rockers.
Engine repair 10
14490S
Position the camshaft grooves as shown in the diagram below.
NOTE : the gasket faces must be clean, dry and free of grease (avoid finger-marks especially).
Use a roller to apply Loctite 518 to the gasket face of the cylinder head cover until it is reddish in co-lour.
Engine repair 10
Refit the cylinder head cover, tightening it to the correct torque.
Tightening method
Fitting Bolt tightening order Bolt slackening order Tightening torque (in daN.m)
Operation n° 1 22-23-20-13 - 0.8
Operation n° 2 1 to 12
14 to 19 21 and 24
- 1.2
Operation n° 3 - 22-23-20-13
-Operation n° 4 22-23-20-13 - 1.2
Engine repair 10
14516S
14497-3R
Refit:
- the oil decanter and torque tighten it to 1.3 daN.m in the
recommen-NOTE : the gasket faces must be clean, dry and free of grease (avoid finger-marks especially).
Use a roller to apply Loctite 518 to the gasket face of the oil decanter until it is reddish in colour.
Engine repair 10
14497-1R
Refit:
- the coils, torque tightening them to 1.3 daN.m,
- the inlet distributor (with new seals), torque tightening to 0.9 daN.m in the recommended order,
- the throttle body, tightening bolts (A) to a tor-que of 1.3 daN.m,
- the air filter unit, tightening the bolts to a tor-que of 0.9 daN.m,
- the camshaft seals, using tool Mot. 1491 (use the old nuts (B)).
Engine repair 10
14490S
Setting the timing
IMPORTANT: it is vital to degrease the end of the crankshaft, the timing sprocket bore, the pressure faces of the accessories pulley and the ends of the camshafts (timing end) and the camshaft pulley bores to prevent slip between the timing, the crankshaft and the camshaft pulleys which would risk damaging the engine.
Fit the camshaft pulleys in place, pretightening the new nuts (the old ones must be renewed) (wi-thout locking the nuts, there should be play of 0.5 to 1 mm between the nut and the pulley).
Position the camshaft grooves as shown in the dia-gram below.
Fit tool Mot. 1496, securing it at the end of the camshafts.
14928R
Check that the crankshaft is against the TDC pin (groove (5) on the crankshaft uppermost).
14489G 14487-1S
Engine repair 10
14487-1R
Position the Renault logo on the camshaft pulley spokes vertically upwards (A). Fit the timing belt to the camshaft sprockets then fit the camshaft pulley locking tool Mot. 1490.
Refit:
- the timing belt,
- the pulley, tightening the mounting bolts to a torque of 4.5 daN.m.
14487-3S NOTE : the accessories crankshaft pulley bolt may be reused if the length under the head does not exceed 49.1 mm, otherwise renew it.
Fit the accessories crankshaft pulley into position, pretightening the bolt (without locking the bolt there should be play of 2 to 3 mm between the bolt and the pulley).
NOTE : do not lubricate the new bolt. If the bolt is being reused, however, it must be lubricated with engine oil.
Engine repair 10
14505-4R1
Belt tension
Check that there is still 0.5 to 1mm play between the nuts and the camshaft pulleys.
Move the mobile index (A’) of the tension wheel 7 to 8 mm in relation to the fixed index (7), using a 6 mm allen key (B).
NOTE : (A) corresponds to the mobile index in the rest position.
Remove the camshaft pulley locking tool Mot.
1490.
Turn the timing face six times using the exhaust camshaft pulley using tool Mot. 799-01.
Slacken the tension wheel nut a maximum of one turn, holding it using a 6 mm allen key.
Align the mobile index (A’) with the fixed index (7) and torque tighten the nut to 2.7 daN.m.
Fit the camshaft pulley locking tool Mot. 1490.
Pretighten the tension wheel nut to a torque of 0.7 daN.m.
14839R
Engine repair 10
14489R
Check that the crankshaft is against the TDC pin Mot. 1489.
Remove the camshaft setting tool Mot. 1496, the camshaft locking tool Mot. 1490 and the TDC pin Mot. 1489.
Checking the tension setting Checking the tension:
Turn the crankshaft clockwise twice (timing side), before the end of the two revolutions, screw the pin Mot. 1489 into the cylinder block and slowly and without jerky movements, adjust the crankshaft until it touches the pin.
Remove the TDC pin.
Check that the tension wheel indices are aligned, otherwise repeat the tensioning procedure.
Slacken the tension wheel nut a maximum of one turn while holding the tension wheel using a 6 mm allen key.
Align the mobile index with the fixed index and tighten the nut to a torque of 2.7 daN.m.
Tighten the accessories crankshaft pulley bolt to a torque of 2 daN.m, then angle tighten by 135° ± 15° (crankshaft against the TDC pin).
Tighten the inlet camshaft pulley nut to a torque of 3 daN.m then angle tighten by 84°.
Tighten the exhaust camshaft pulley nut to a tor-que of 3 daN.m then angle tighten by 84°.
Engine repair 10
14490S
Checking the setting
Ensure that the tension wheel indices are correctly positioned before checking the setting of the ti-ming.
Screw pin Mot. 1489 into the cylinder block then position and retain the crankshaft against the pin.
Fit (without forcing) tool Mot. 1496 for setting the camshafts (the camshaft grooves must be horizon-tal). If the tool does not engage, the timing must be reset and the tension adjusted.
Refit:
- the TDC pin plug,
- the upper timing cover, tightening the bolts and nuts to a torque of 4.1 daN.m,
14487-5S
- the intermediate timing cover.
14487-6S
Engine repair 10
14890R
Remove the engine from support Mot. 790-03.
Refit:
- the coolant pipe with a new seal,
- the multifunction mounting (check that it touches the sump at (A) before tightening) then torque tighten the bolts (see table below).
14492-2R
Refit new plugs for:
- the inlet camshaft (Mot. 1487), - the exhaust camshaft (Mot. 1488).
Bolts Tightening torque
1 5.3 daN.m
2 2.1 daN.m
3 11 daN.m
Refit:
- the air conditioning compressor, tightening the bolts to a torque of 2.1 daN.m,
- the alternator, tightening the bolts to a torque of 2.1 daN.m,
- the power assisted steering pump, tightening the bolts to a torque of 2.1 daN.m,
- the accessories belt.
With air conditioning
To fit the belt, pivot the wrench to the left.
Lock the tension wheel using a 6 mm allen key (1).
Engine repair 10
Alternator and power assisted steering
14977R
Without air conditioning
The belt is tensioned using bolt (1) (the two ten-sion wheel mounting bolts are slackened) then tighten nut (2).
Tension (US = SEEM units)
Multitooth power assisted steering belt
Fitting 108 ± 6
A Crankshaft
B Power assisted steering pump C Alternator
T Tension wheel
→ Point for checking belt tension
NOTE : the accessories belt has five teeth, while the alternator pulley and the PAS pump pulley have six; when fitting the belt, it is therefore vital to ensure that the tooth at the end of the pulleys at (E) remains free.
14888R